Semiconductor light emitting device providing graded brightness

ABSTRACT

A semiconductor light emitting device includes a semiconductor lamination including a p-type semiconductor layer, an active semiconductor layer, and an n-type semiconductor layer; opposing electrode structure including a first electrode structure formed above the p-type semiconductor layer, and a second electrode structure formed above the n-type semiconductor layer; and brightness grade producing structure including a surface layer of at least one of the p-type semiconductor layer and the n-type semiconductor layer and producing brightness grade gradually changing from one edge to opposite edge of light output plane.

CROSS REFERENCE TO RELATED APPLICATION

This application is based on and claims priority of Japanese patentapplication 2012-201774, filed on Sep. 13, 2012.

FIELD OF THE INVENTION

This invention relates to a semiconductor light emitting device and itsmanufacture.

RELATED ART

Nitride semiconductor light emitting diodes (LED) such as GaN diodes canemit ultraviolet or blue lights. By utilizing fluorescent material orphosphor, these LED's can emit white lights. White light emitting LED'sare used, for example, for illumination or head light for vehicles.

Generally, sapphire is used as growth substrate for nitridesemiconductor layers. Sapphire is an insulator and hence, when thesapphire substrate exists, n-side and p-side electrodes should be formedon the grown layers. Sapphire has a relatively low thermal conductivity,and is relatively poor in heat transfer. Recently, development has beendone to remove the sapphire growth substrate by laser lift off (LLO) orpolishing. When the sapphire substrate is removed, an n-type layer and ap-type layer can be exposed, and an n-side electrode and a p-sideelectrode can be formed thereon.

Techniques of forming brightness distribution in the output lights froman LED have been developed (for example, see JP-A 2012-059523).Brightness distribution for head light of an automobile is arranged insuch configuration that brightness is at a constant value in horizontaldirection, and gradually decreases from lower side to upper side invertical direction.

SUMMARY OF THE INVENTION

Embodiments are intended to provide a semiconductor light emittingdevice which produces brightness grade or inclination in one direction.The brightness may be kept constant in a direction perpendicular to theone direction.

A semiconductor light emitting device includes a semiconductorlamination including a p-type semiconductor layer, an activesemiconductor layer, and an n-type semiconductor layer; opposingelectrode structure including a first electrode structure formed abovethe p-type semiconductor layer, and a second electrode structure formedabove the n-type semiconductor layer; and brightness grade producingstructure including a surface layer of at least one of the p-typesemiconductor layer and the n-type semiconductor layer and producingbrightness grade gradually changing from one edge to opposite edge oflight output plane.

A method for manufacturing a semiconductor light emitting device capableof emitting lights with brightness grade includes growing asemiconductor lamination on a growth substrate, the semiconductorlamination including a p-type semiconductor layer, an activesemiconductor layer, and an n-type semiconductor layer; formingbrightness grade producing structure including a surface layer of atleast one of the p-type semiconductor layer and the n-type semiconductorlayer and producing brightness grade gradually changing from one edge toopposite edge of light output plane; and forming opposing electrodestructure including a first electrode structure formed above the p-typesemiconductor layer, and a second electrode structure formed above then-type semiconductor layer.

The object and advantages of the invention will be realized and attainedby means of the elements and combinations particularly pointed out inthe claims.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and are not restrictiveof the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic diagram of a segment to be formed in lightemitting plane, FIGS. 1B, 1C, and 1D are a plan view, an equivalentcircuit diagram, and a cross section of an LED.

FIGS. 2A, 2B, and 2C are a plan view and cross sections of an LED havingdistributed low resistivity regions LR and high resistivity regions HR,which produce brightness grade or inclination.

FIGS. 3A-3N are cross sections of semiconductor structure illustratingprocesses for forming an LED array.

FIGS. 4A-4F are cross sections of semiconductor structure illustratingprocesses for forming brightness grade producing structure according toa first embodiment.

FIG. 5 is a cross section of a semiconductor structure according to amodification.

FIGS. 6A-6E are cross sections of semiconductor structure illustratingprocesses for forming brightness grade producing structure according toa second embodiment.

FIGS. 7A-7D are cross sections of semiconductor structure illustratingprocesses for forming brightness grade producing structure according toa third embodiment.

FIGS. 8A-8D are cross sections of semiconductor structure illustratingprocesses for forming brightness grade producing structure according toa fourth embodiment.

FIG. 9 is a schematic diagram illustrating a head light assembly.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1A is a schematic plan view of a light emitting segment. In ahorizontally long rectangular light output segment SEG, there are formeda triangular high resistivity region HR which has a height graduallydecreasing from the left side to the right side, and a pair oftriangular low resistivity regions LR sandwiching the high resistivityregion HR from the upper and lower sides, each of the low resistivityregions LR having a height gradually increasing from the left side tothe right side. The high resistivity region HR has significantly higherresistivity than that of the low resistivity region LR. The height ofone segment SEG is set small, and a plurality of segments will bestacked in vertical direction in the figure to produce horizontalresistance distribution gradually decreasing from the left side to theright side in the figure.

FIG. 1B is a plan view of a light emitting diode (LED) array 100including four semiconductor light emitting (LED) elements 101 formed ona support substrate 10 such as a silicon substrate formed with aninsulating film such as silicon oxide film, and connected in series. Inthis figure, segment SEG as illustrated in FIG. 1A is orientedvertically, and a multiplicity of vertically long segments SEG arestacked and aligned in horizontal direction. Low resistivity regions LRof adjacent segments will be combined to form one low resistivity regionLR. The detailed structure and the manufacture thereof will be describedlater.

FIG. 1C is an equivalent circuit diagram of the four LED elements in theLED array 100. Four LED elements 101 are connected in series. The n-sideelectrode 11 of the LED element 101, except the leftmost one, isconnected to the p-side electrode of the left side adjacent LED element101, and the n-side electrode 11 of the leftmost LED element isconnected to the n-side current supply pad 13 n. The p-side electrode 12of the rightmost LED element 101 is connected to the p-side currentsupply pad 13 p.

FIG. 1D is schematic cross section of basic structure of an LED element101 along linear segment ab depicted in FIG. 1B. Each of the LEDelements 101 includes a GaN series light emitting portion (devicestructure lamination) 2 including an n-type GaN layer 22, an activelayer 23, and a p-type GaN layer 24. The term “GaN series” means alloyor mixed crystal system of AlGaInN. The LED element further includes ap-side electrode 12 formed on a rear surface of the p-type GaN layer 24and exposed along a first lengthwise side of the device structurelamination 2.

An insulating film 7 made of silicon oxide is formed on the LED islandsincluding the device structure lamination 2, for protecting the surface.Openings are formed in the insulating film 7 on the upper surface of then-type GaN layer 22 and on a stripe region of p-side electrode 12outside the device structure lamination 2. An n-side common electrode 11is disposed in parallel with and spaced at a constant distance from asecond lengthwise side opposite to the first lengthwise side of the LEDelement 101.

A plurality of contact and wiring electrodes 8 are disposed on a frontsurface of the n-type GaN layer 22 and on the insulating layer 7 inparallel with the short side of the device structure lamination 2, andconnected to the n-side common electrode 11. The assembly of the contactand wiring electrodes 8 and the n-side common electrode 11 may have sawtooth shape as illustrated in FIG. 1B.

As illustrated in FIG. 1D, a reflecting metal electrode 3 made forexample of Ag or Ag alloy is formed on the rear surface of the p-typeGaN layer 24. Lights downwardly proceeding from the active layer 23 willbe reflected upward by the reflecting metal electrode 3. An etch stopperlayer 4 made for example of silicon oxide is formed on a peripheralportion of the p-type GaN layer 24 surrounding the reflecting metalelectrode 3. The etch stopper layer 4 serves as an etch stopper inetching for isolating the respective LED elements. A first adhesionmetal layer 5 is formed above the p-type GaN layer 24, covering thereflecting metal electrode 3 and the etch stopper layer 4. Thereflecting metal electrode 3 and the adhesion metal layer 5 constitute ap-side electrode 12. The n-side electrode 11 of adjacent LED elementextends on the p-side electrode 12 exposed in the opening.

The number of LED elements in the array is not limited to four, and maybe increased or decreased according to necessity. The connection of theLED elements is not limited to a single series connection. For obtaininga high output power, it is preferable to assemble a plurality of LEDelements. They may be connected in series, in parallel, or in paralleland series, or in other configurations.

The respective LED elements may be shaped in horizontally longrectangular, vertically long rectangular, or square shape. The contactand wiring electrode 8 may have ladder shape, lattice shape, radialshape, or other shapes, as well as the comb tooth shape.

FIGS. 2A, 2B, and 2C illustrate the configuration of high resistivityregions HR and low resistivity regions LR, for establishing brightnessgrade or inclination according to a first embodiment.

As illustrated in FIG. 2A, high resistivity regions HR and lowresistivity regions LR are alternatingly disposed horizontally in such amanner that the horizontal total width of the high resistivity regionsHR decreases from the top to the bottom, while the horizontal totalwidth of the low resistivity regions LH increases from the top to thebottom. Therefore, the average resistivity decreases from the top to thebottom. Each width of the high and low resistivity region is set sosmall that the people does not sense the respective width, but sensesonly the average value. In the first embodiment, the high resistivityregion HR is formed by selectively irradiating the p-type layer 24 withplasma of an inert gas, using transparent electrode pattern as a mask.

FIGS. 2B and 2C depict horizontal cross sectional structures alongsegments at different vertical heights, c1-d1 and c2-d2 denoted in FIG.2A. A transparent electrode layer made of ITO is formed on a surface ofthe p-type GaN layer 24 and patterned in such a manner that the ITOpatterns 3 a cover the regions which will form low resistivity regionsLR. The width of the ITO pattern 3 a illustrated in FIG. 2B (alongc1-d1, at a lower position in FIG. 2A) is wider than that of the ITOpattern 3 a illustrated in FIG. 2C (along c2-d2, at a higher position inFIG. 2A). The patterning of the ITO layer may be done by wet etchingusing photoresist mask. The patterned ITO layer will be subjected tothermal annealing in oxygen containing atmosphere.

The surface of the p-type GaN layer 24 exposed between pairs of theadjacent ITO patterns 3 a is subjected to irradiation of plasma of aninert gas to form plasma damaged regions 24 b which will constitute highresistivity regions HR. A reflecting metal electrode 3 b such as Ag orAg alloy layer is formed on the p-type GaN layer 24 covering the ITOpatterns 3 a.

The plasma damaged regions 24 b form the high resistivity regions HR ofcontact resistance of the order of 1×10⁻² Ωcm, while the p-type GaNlayer covered with the ITO patterns may form low resistivity regions LRof contact resistance of the order of 1×10⁻⁵ Ωcm. Practically, it may beapproximated that current flowing through the high resistivity regionsis negligibly small compared to current flowing through the lowresistivity regions.

The contact and wiring electrodes 8 on the n-type GaN layer 22 may belocated at the center of the high resistivity regions HR. In such case,the high resistivity regions HR may serve to diffuse the currentsupplied from the contact and wiring electrodes 8. Description will bemade on the processes for manufacturing LED array with brightness gradeor inclination.

As depicted in FIG. 3A, a growth substrate (for example, a C planesapphire substrate) 1 capable of growing Al_(x)Ga_(y)In_(z)N (0≦x≦1,0≦y≦1, 0≦z≦1, x+y+z=1) by organic metal chemical vapor deposition(MOCVD) is prepared. Semiconductor lamination structure comprisingAl_(x)Ga_(y)In_(z)N (0≦x≦1, 0≦y≦1, 0≦z≦1, x+y+z=1) layers 20, 21, and 2is grown on the growth substrate 1 by MOCVD.

More specifically, the sapphire substrate 1 is loaded in a MOCVD system,and heating (thermal cleaning) is done, for example, at 1000° C. for 10minutes in hydrogen atmosphere. Then, a low temperature buffer layer(GaN layer) 20 is grown at a low temperature, for example at about 500°C., by supplying TMG (tri-methyl-gallium) 10.4 micromol/min, NH₃ 3.3 SLM(standard liter per minute), for three minutes. The growth substrate 1is a single crystal substrate having lattice constant capable ofepitaxially growing GaN series layers, for example a C-plane sapphiresubstrate. The growth substrate is selected from the materialstransparent for the light at the wavelength of 362 nm, which is theabsorption edge of the GaN, for enabling removal of the substrate bylaser lift-off. Spinel, SiC, ZnO etc. may also be used as well assapphire.

Then, the substrate 1 is heated to 1000° C. and maintained thereat for30 seconds to crystallize the low temperature buffer layer 20. At thesame temperature, an underlying GaN layer (undoped GaN layer) 21 isgrown to a thickness of about 5 micrometers by supplying TMG 45micromol/min, NH₃ 4.4 SLM for 100 minutes. Commonly, the undoped GaNlayer is grown to a thickness in a range of 1-3 micrometers.

Continuously at 1000° C., a Si-doped n-type GaN layer 22 is grown to athickness of about 5 micrometers by supplying TMG 45 micromol/min, NH₃4.4 SLM, and SiH₄ 2.7×10⁻⁹ micromol/min, for 100 minutes.

Then, an active layer 23, more specifically multi-quantum-well (MQW)structure, is grown at 700° C. Here, an InGaN/GaN lamination is set asone period, and growth of 5 periods is performed. In one period, anInGaN well layer of a thickness of about 2.2 nm is grown by supplyingTMG 3.6 micromol/min, TMI (tri-methyl-indium) 10 micromol/min, and NH₃4.4 SLM, for 33 seconds, and a GaN barrier layer of a thickness of about15 nm is grown by supplying TMG 3.6 micromol/min, and NH₃ 4.4 SLM, for320 seconds.

Then, a p-type layer 24, more specifically combination of a Mg-dopedp-type AlGaN layer (clad layer) and a Mg-doped p-type GaN layer (contactlayer), is grown. Ga_(1-x-y)Al_(x)In_(y)N may be called “GaN series”.

Namely, after the growth of the active layer 23, the temperature israised to 870° C., and a Mg-doped p-type AlGaN layer (clad layer) isgrown to a thickness of about 40 nm by supplying TMG 8.1 micromol/min,TMA (tri-methyl-aluminium) 7.5 micromol/min, NH₃ 4.4 SLM, and Cp₂Mg(bis-cyclopentadienyl Mg) 2.9×10⁻⁷ micromol/min for 5 minutes. Then, aMg-doped p-type GaN layer (contact layer) is grown to a thickness ofabout 150 nm by supplying TMG 18 micromol/min, NH₃ 4.4 SLM, and Cp₂Mg2.9×10⁻⁷ micromol/min for 7 minutes.

In the p-type layer 24, the doped impurity Mg forms bond with hydrogenintroduced in the film in the growth step to form Mg—H bond which cannotserve as p-type impurity. The Mg doped p-type layer has highresistivity. Activation process is done for expelling hydrogen from thelayer 24. More specifically, heating at or above 400 degrees centigradein vacuum or inert gas atmosphere is done using a heating furnace.

As depicted in FIG. 3B, a p-side electrode (reflecting electrode) 3 ofpredetermined shape is formed on the surface of the p-type GaN serieslayer 24. The p-side electrode 3 may comprise a patterned contact layer3 a of indium tin oxide (ITO) and a continuous Ag or Ag alloy layer 3 bcovering the patterned ITO layer 3 a, as illustrated in FIGS. 2B and 2C.Here, the formation of the p-side electrode 3 is accompanied withformation of high resistivity region and low resistivity region, whichwill be described referring to FIGS. 4A-4F.

As depicted in FIG. 4A, an ITO film 3 a is deposited on a surface of thep-type GaN layer 24 to a thickness of 15 nm by sputtering an ITO targetunder the conditions of Ar: 50 sccm, O₂: 0.5 sccm, and pressure: 0.5 Pa.

As depicted in FIG. 4B, a photo-resist mask PR of desired shape isformed on the ITO film 3 a.

As depicted in FIG. 4C, the ITO film 3 a is wet etched using thephoto-resist mask PR as an etching mask to leave patterned ITO film 3 aon the surface of the p-type GaN layer 24. Since the ITO film has notbeen subjected to thermal treatment in oxygen containing atmosphere,unnecessary portion of the ITO film can be completely removed.

As depicted in FIG. 4D, the photo-resist mask PR is removed. Afterremoving the photo-resist mask PR, the ITO film 3 a is subjected toanneal treatment in oxygen containing atmosphere at a temperaturebetween 400° C. and 700° C. (preferably between 450° C. and 600° C.).Contact resistance and transparency of the ITO film 3 a are improved bythe ITO anneal treatment.

As depicted in FIG. 4E, the surface regions of the p-type GaN layer 24exposed between (or outside) the ITO film patterns are irradiated byplasma of an inert gas, to form high resistivity regions 24 b in whichcurrent is hard to flow. As the inert gas, Ar, He, N₂, CF₄, and H₂ canbe used. The contact resistance of the p-type GaN layer may be 1×10⁻⁵Ωcm². The contact resistance of the plasma-irradiated region can bearranged to be higher than 1×10⁻² Ωcm², where current is practicallyhard to flow. The thickness of the high resistivity region is selectedto be less than the thickness of the p-type GaN layer 24.

As depicted in FIG. 4F, an Ag layer 3 b is deposited to a thickness ofabout 200 nm to continuously cover the ITO film 3 a and the highresistivity regions 24 b, by electron beam (EB) deposition. As a result,a reflection electrode 3 comprising the ITO film 3 a and the reflectingmetal (Ag) film 3 b is formed. The reflecting electrode 3 has highreflectivity at the emission wavelength, and reflects light coming fromthe active layer 23 through the p-type layer 24 back toward the n-typelayer 22. If the Ag layer is too thin, sufficient reflectivity cannot beobtained. Thus, the Ag layer preferably has a thickness of 100 nm orthicker. The formation of the reflection metal layer can also be done bysputtering. The reflection electrode may also be patterned by well-knownlift-off. The reflection electrode 3 may also be formed of Pt, Pd, Ni,Ti, Al, and alloys thereof, as well as Ag.

The ITO film 3 a serves as a contact layer and has low contactresistance. The region where the ITO film is formed constitutes lowresistivity region LR. The plasma damaged region 24 b has high contactresistance and constitutes high resistivity region HR. Electric currentsupplied from the electrode 8 selectively flows through the lowresistivity region LR. The low resistivity region LR produces higherbrightness than the high resistivity region HR. Planar distribution ofthe low resistivity region LR and the high resistivity region HR asdepicted in FIG. 2A will produce brightness change which graduallyincreases from the lower side to the upper side. Now descriptioncontinues referring to FIGS. 3C-3N.

As depicted in FIG. 3C, an etching stopper layer 4 made of SiO₂preferably of a same thickness as the reflection electrode 3 is formedon the device structure lamination 2 (p-type GaN layer 24) surroundingthe reflection electrode 3, by sputtering and lift-off. The etchingstopper layer 4 serves as an etch stopper in the etching step asdescribed later referring to FIGS. 3L and 3M.

As depicted in FIG. 3D, a first adhesion layer 5 made of an Au film of200 nm thick is formed on a region including the reflection electrode 3and the etching stopper layer 4. The first adhesion layer 5 may beformed after a diffusion preventing layer is formed on the areaincluding the reflection electrode 3 and the etching stopper layer 4. Incase of forming a diffusion preventing layer, for example, a diffusionpreventing layer made of a TiW film of 300 nm thick is formed bysputtering. The diffusion preventing film serves to prevent diffusion ofa material used as the reflection electrode 3. When Ag is included inthe reflection electrode, those materials as Ti, W, Pt, Pd, Mo, Ru, Ir,Au, and alloys thereof can be used.

As depicted in FIG. 3E, the device structure lamination 2 is dividedinto a plurality of rectangular elements (see FIG. 1A) by dry etchingusing a resist mask and chlorine gas. Side walls of the divided devicestructure lamination 2 take forward taper shape with respect to thegrowth substrate, the angle between the side wall and the bottom surfaceof the element being less than 90 degrees.

As depicted in FIG. 3F, a support substrate 10, for example made ofsilicon, is prepared. Thermal oxidation is done on the support substrateto form a thermal oxide insulating film 9. The thickness of theinsulating film 9 is enough if sufficient insulation is secured.

A second adhesion layer 6 made of AuSn (Sn: 20 wt %) having a thicknessof 1 micrometer is formed on the support substrate 10 by resistanceheating. The support substrate 10 is preferably formed of a materialhaving a thermal expansion coefficient near those of sapphire(7.5×10⁻⁶/K) and GaN (5.6×10⁻⁶/K), and a high thermal conductivity. Forexample, Si, AlN, Mo, W, CuW etc. may be used. The first adhesion layer5 and the second adhesion layer 6 may be formed of metals includingAu—Sn, Au—In, Pd—In, Cu—In, Cu—Sn, Ag—Sn, Ag—In, Ni—Sn, etc. capable ofmelt adhesion, or metals including Au capable of diffusion adhesion.

As depicted in FIG. 3G, the second adhesion layer 6 may be patterned byutilizing lift-off. First, a photoresist (for example photoresist AZ5200available from Clariant Co.) is coated on a whole surface of a thermallyoxidized support substrate 10, and is subjected to prebaking on a hotplate set under 90° C., for about 90 seconds in air. Then, thephotoresist layer is pattern-exposed to ultraviolet (UV) lights at firstexposure amount of 17 mJ. The photoresist film after the exposure issubjected to reversal baking treatment in air at 120° C., for 90 secondsto cause thermal cross-linking. Then, UV lights are irradiated on thewhole surface of the support substrate 10 at reversal exposure amount600 mJ. Then, the photoresist film is immersed in developing liquid for130 seconds to perform developing, to obtain desired photo-resist maskPR1 (in areas except the area of the second adhesion layer 6). Thephoto-resist mask PR1 thus formed has peripheral portion with reversetaper shape (upwardly broadening shape). The resist material and theconditions of photolithography can be changed appropriately.

A metal lamination 6 comprising Ti (150 nm)/Ni (50 nm)/Au (100 nm)/Pt(200 nm)/AuSn (1000 nm, Sn: 20 wt %) is deposited on the supportsubstrate by resistance heating, and subjected to lift-off to leave asecond adhesion layer 6 having a forwardly tapered peripheral shape withrespect to the support substrate 10 (upwardly narrowing cross section),as depicted in FIG. 3H.

The above-described process of manufacturing the adhesion layer 6 is notlimitative. The lamination structure of the adhesion layer may bechanged. The second adhesion layer 6 may also be patterned by dryetching or wet etching, as well as lift-off.

As depicted in FIG. 3I, the first adhesion layer 5 and the secondadhesion layer 6 are brought into pressed contact with a pressure of 3MPa, are heated to 300° C., maintained for 10 minutes, and then cooleddown to room temperature, achieving melt adhesion. An adhesion layer isformed by this melt adhesion.

As depicted in FIG. 3J, UV excimer laser lights are irradiated from therear surface side of the sapphire substrate 1, to heat and decompose thebuffer layer 20. The sapphire substrate 1 is separated (removed) fromthe device structure lamination 2 by laser lift-off. KrF excimer laseremitting lights of wavelength 248 nm may be used as the laser. Laserpower may be about 800 mJ/cm². Removal of the growth substrate 1 mayalso be done by other methods than laser lift-off, such as etching.

As depicted in FIG. 3K, metal Ga generated by laser lift-off is removedby hot water etc., and surface treatment with chloric acid is done. Thesurface of the n-type GaN layer 22 is exposed by these treatments. Thesurface treatment is enough if it can etch nitride semiconductor. Acidicand alkaline agents such as phosphoric acid, sulfuric acid, KOH, NaOH,etc. can be used. Surface treatment may be also done by dry etchingusing Ar plasma or chlorine series plasma, or by polishing. The surfaceof the n-type semiconductor layer 22 may be subjected to Cl or Artreatment using dry etching apparatus such as RIE apparatus, or may beplanarized by polishing using chemical mechanical polishing (CMP)apparatus, to remove laser traces or laser-damaged layers. Further, theexposed surface of the n-type semiconductor layer 22 may be subjected tomicro-cone (surface structure) process which improves light outputefficiency.

As illustrated in FIG. 3L, a photo-resist mask PR3 is formed whichexposes peripheral portions of the device structure lamination 2.Subsequently, dry etching is carried out using chlorine gas to etch theperipheral portions of the device structure lamination 2 that are notcovered by the photo-resist mask PR3, until the etching stop layer 4 isexposed.

As illustrated in FIG. 3M, the side wall of the device structurelamination 2 has a forwardly tapered shape in which the planar crosssection of the device structure lamination 2 decreases towards the top,assuming the support substrate 10 being located at the bottom. In thisprocess, the insulating film 9 on the surface of the support substrate10 is also etched to have forward taper using the etching stopper layer4 as a mask. Forwardly tapered shape is free from overhanging orvertical side surface. The existence of the etching stopper layer 4 canincrease the reliability of the device. The etching stopper layer 4protects the underlying adhesion layer to be erroneously etched andproduced deposition causing short-circuit.

As illustrated in FIG. 3N, a protection film (insulation film) 7 made ofSiO₂ is formed by, for example, chemical vapor deposition (CVD) to coverthe entire upper surface of the element formed in the aforementionedsteps, and then part of the protection film 7 formed on the devicestructure lamination 2 is etched with buffered hydrofluoric acid toexpose part of the surface of the device structure lamination 2 (surfaceof the n-type GaN layer 22 exposed by peeling off the transparentsubstrate 1).

A photo-resist mask is formed, and a Ti layer of a thickness of 1 nm, anAl layer of a thickness of 200 nm, a Ti layer of a thickness of 100 nm,a Pt layer of a thickness of 200 nm, and an Au layer of a thickness of2.5 μm are sequentially deposited in this order by electron beamdeposition and patterned by lift-off to form wiring/electrode 8 having,for example, a width of about 10 μm, the wiring 8 electricallyconnecting the n-type GaN layer 22 and the p-side electrode 12 of theadjacent element. The wirings 8 form Ohmic contact with the uppersurface of the n-type GaN layer 22, and continuously extend on thetapered side walls of the device structure lamination 2 and the adhesionlayers 5 and 6 through the insulating film 7. Since the wirings 8 areformed on flat surfaces or forwardly tapered side walls, they can beformed without causing disconnection during and after manufacture. Thewiring 8 preferably has a width of 20 μm or lower and 3 μm or higher.

Then, the support substrate 10 may be divided by laser scribing ordicing. Finally, fluorescent material is coated on the surface of theLED array 100, to form the fluorescent layer 108 as depicted in FIG. 9.For example, resin containing yellow fluorescent particles is coated onblue GaN LED elements to form the fluorescent layer 108.

In the above embodiment, crystal growth is done in the order of n-typelayer/active layer/p-type layer, and high resistivity regions are formedin the p-type layer. The crystal growth may be done in the order ofp-type layer/active layer/n-type layer, and high resistivity regions maybe formed in the n-type layer. At least one of the p-type layer and then-type layer may be used to form high resistivity regions. A pluralityof nitride semiconductor light emitting (LED) elements 101 are disposedon a single support substrate 10, and connected in series to constitutean LED array 100. The LED elements may be connected in parallel instead,or may be separated individually.

FIG. 5 illustrates an alteration structure. An electrode 13 is formed ona rear surface of a conductive support substrate 10. Electrode 8 isformed on the surface of the n-type GaN layer 22 and is connected to anelectrode pad Pd also formed on the upper surface of the n-type GaNlayer 22. Current is supplied between the pad Pd and the electrode 13.Other structures including the low resistivity region and the highresistivity region are similar to the foregoing embodiment.

FIGS. 6A-6E illustrate processes of the second embodiment, to replacethe processes illustrated in FIGS. 4A-4F of the first embodiment. Otherpoints are similar to the first embodiment.

As illustrated in FIG. 6A, a photo-resist mask PR of predeterminedpattern (configuration) corresponding to low resistivity regions isformed on a p-type GaN layer 24 of a device structure lamination. Theregion(s) covered by the photo-resist mask will form low resistivityregion(s), and the regions exposed outside the photo-resist mask willform high resistivity regions.

As illustrated in FIG. 6B, gas plasma GP of an inert gas is excited andis irradiated on the p-type GaN layer 24 of the device structurelamination. The p-type GaN layer 24 outside the photo-resist mask PR isexposed to the gas plasma GP, influenced by the gas plasma GP, and istransformed into plasma damaged region 24 b. The p-type GaN layer 24under the photo-resist mask PR is protected by the mask PR from theplasma attack. The region irradiated by the plasma will form highresistivity region HR having a contact resistance of, for example 1×10⁻²Ωcm² or above. The thickness of the high resistivity region HR is setthinner than the thickness of the p-type GaN layer 24. Gases such as Ar,He, N₂, CF₄, and H₂ may be used as the inert gas.

As illustrated in FIG. 6C, the photo-resist mask PR is removed. Thewhole surface of the p-type GaN layer 24 is exposed, wherein the highresistivity regions HR are selectively formed between the lowresistivity regions LR.

As illustrated in FIG. 6D, a transparent electrode layer 3 a made of ITOis formed on the surface of the p-type GaN layer 24 including the highresistivity regions HR and low resistivity regions LR. For example, anITO film 3 a is sputtered in a sputtering apparatus under the conditionsof Ar: 50 sccm, O₂: 0.5 sccm, and pressure: 0.5 Pa, to a thickness of 15nm. The ITO film 3 a is subjected to thermal treatment in an oxygencontaining atmosphere at a temperature between 400° C. and 700° C.(preferably between 450° C. and 600° C.). Contact resistance andtransparency of the ITO film are improved by the anneal treatment.

As illustrated in FIG. 6E, an Ag or Ag alloy film 3 b is deposited onthe ITO film 3 a by electron beam deposition to a thickness of about 200nm. The Ag reflecting metal film 3 b and the ITO film 3 a collectivelyconstitute a reflecting metal electrode 3, which reflect lights emittedfrom the active layer 23 and coming from the lower side toward thedownward direction. The reflecting metal film having high reflectivityto the emitted lights may also be formed of Pt, Pd, Ni, Ti, Al, andalloys thereof, as well as Ag. The Ag film preferably has a thickness of100 nm or more, and may be formed by sputtering as well as by electronbeam deposition.

The second embodiment as described above, selectively forms plasmadamaged regions in predetermined areas of the p-type GaN layer 24, andafter removing the mask for plasma irradiation, forms an ITO film 3 atotally on the p-type GaN layer 24, and a reflecting metal film 3 b isformed on the continuous surface of the ITO film 3 a, above the p-typeGaN layer 24. The combination of the ITO film 3 a and the Ag or Ag alloyreflecting metal electrode 3 b may be replaced with a combination of athin Ni or NiO film and an Ag or Ag alloy film.

In the second embodiment, the plasma damaged regions 24 b constitutehigh resistivity regions HR, and the ITO film 3 a formed on p-type GaNregions other than the plasma damaged regions 24 b serves as a contactlayer and constitutes low resistivity regions LR. Currents supplied fromthe electrodes 8 are allowed to flow selectively through the lowresistivity regions LR, producing higher brightness than that in thehigh resistivity regions HR.

When the low resistivity regions LR and the high resistivity regions HRare configured to distribute as in the plan view of FIG. 2A, brightnessdistribution gradually decreasing from the lower side to the upper sidecan be provided. Head lights of automobiles are required to illuminatenear portions more brightly than far portions. The above-mentionedbrightness distribution is fitted for a head light of an automobile.

FIGS. 7A-7D illustrate processes of the third embodiment, to replace theprocesses illustrated in FIGS. 4A-4F of the first embodiment. Otherpoints are similar to the first embodiment.

As illustrated in FIG. 7A, a photo-resist mask PR is formed on thesurface of a p-type GaN layer 24. The mask PR has a pattern of lowresistivity region LR, with openings corresponding to high resistivityregions HR, as illustrated in FIG. 2A. Then, a silicon oxide(transparent insulating) film 3 c is deposited on the p-type GaN layer24 partially covered by the photo-resist mask PR. In the openings of thephoto-resist mask PR, the insulating film 3 c is formed on the surfaceof the p-type GaN layer 24. The photoresist mask PR protects theunderlying surface of the p-type GaN layer 24 from being directlycovered by the insulating film 3 c, and allows deposition of theinsulating film 3 c thereon.

As illustrated in FIG. 7B, the photo-resist mask PR is removed, and theinsulating film 3 c deposited on the photo-resist mask PR is removed bylift-off to expose the surface of low resistivity regions LR. Theinsulating films 3 c which have been formed in the openings of thephotoresist mask (high resistivity regions) in contact with the p-typeGaN layer 24 are left.

As illustrated in FIG. 7C, a transparent electrode layer 3 a made of ITOis formed on the insulating film 3 c and on the surface of the p-typeGaN layer 24 outside the insulating film 3 c (high resistivity regionsHR). For example, an ITO film 3 a is sputtered to a thickness of 15 nmin a sputtering apparatus under the conditions of Ar: 50 sccm, O₂: 0.5sccm, and pressure: 0.5 Pa. The ITO film 3 a is subjected to thermaltreatment in an oxygen containing atmosphere at a temperature between400° C. and 700° C. (preferably between 450° C. and 600° C.). Contactresistance and transparency of the ITO film are improved by the annealtreatment. The ITO film 3 a in direct contact with the p-type GaN layer24 will form contact layers of low contact resistance. The insulatingfilms 3 c between the ITO film 3 a and the p-type GaN layer 24constitute barriers for carrier transfer, and produce high resistivityregions HR.

As illustrated in FIG. 7D, an Ag or Ag alloy film 3 b is deposited onthe ITO film 3 a by electron beam deposition to a thickness of about 200nm to form a reflecting metal film. The Ag reflecting metal film 3 b andthe ITO film 3 a collectively constitute a reflecting metal electrode 3,which reflects lights emitted from the active layer 23 and coming fromthe lower side.

The reflecting metal film 3 having high reflectivity to the emittedlights may also be formed of Pt, Pd, Ni, Ti, Al, and alloys thereof, aswell as Ag. The Ag film preferably has a thickness of 100 nm or more,and may be formed by sputtering as well as by electron beam deposition.The combination of the ITO film 3 a and the reflecting metal film 3 bmay be replaced with a combination of a thin Ni or NiO film and an Agfilm.

In the third embodiment, regions where insulating films 3 c are formedconstitute high resistivity regions HR, and the ITO films 3 a directlycontacting the p-type GaN layer 24 outside the insulating films 3 cserve as contact layers, constituting low resistivity regions LR.Currents supplied from the electrodes 8 are allowed to flow selectivelythrough the low resistivity regions LR, producing higher brightness thanthat in the high resistivity regions HR.

FIGS. 8A-8D illustrate processes of the fourth embodiment, to replacethe processes illustrated in FIGS. 4A-4F of the first embodiment. In thefourth embodiment, the resistivity of the p-type GaN layer 24 is changedalong one direction by changing the degree of plasma damage. Otherpoints are similar to the first embodiment.

As illustrated in FIG. 8A, a photo-resist mask PR having a thicknesschanging in one direction, decreasing thickness from the left edge tothe right edge, is formed on a p-type GaN layer 24. Such a photo-resistmask may be formed by exposing a photoresist layer with graded opticaldensity and developing the exposed photo-resist layer. The photo-resistmask PR has property of being consumed by plasma irradiation.

As illustrated in FIG. 8B, gas plasma GP of an inert gas is irradiatedon the photo-resist mask PR. The photo-resist mask PR is consumed byplasma. Since the photo-resist mask PR has a thickness distributionchanging in one direction, the photo-resist mask PR is consumed from athinnest portion to gradually thicker portions to expose the underlyingp-type GaN layer 24 gradually wider from the left edge in the figure.The portion exposed earlier will receive plasma attack longer, and willproduce heavier plasma damage. The degree of plasma damage may appear inthe degree of crystal damage or in the depth of damaged region. In thefigure, depth of the plasma damaged region 24 b represents the degree ofplasma damage.

As illustrated in FIG. 8C, when the photo-resist mask PR is totallyconsumed, the plasma damaged region 24 b is formed on the total surfacearea of the p-type GaN layer 24 with gradually changing degree of plasmadamage. The area of heavier plasma damage will exhibit larger contactresistance.

As illustrated in FIG. 8D, an Ag layer 3 b is deposited on the p-typeGaN layer 24 with plasma damaged regions 24 b. The damage of the plasmadamaged regions 24 b becomes heavier and the contact resistance of theAg layer 3 b becomes larger, as the position shifts rightward, therebyestablishing brightness distribution gradually increasing from the rightedge to the left edge in the figure.

FIG. 9 is a diagram showing a structure of automotive lighting(headlamps) 50 equipped with the LED arrays 100 according to theembodiment of the present invention.

As shown in FIG. 9, a projection optical system 51 can be equipped witha multireflector (reflection surfaces) 103 and a projection lens 105, toshare the projection lens 105 with a plurality of LED arrays 100. Theheadlamp 50 shown in FIG. 9 includes light sources formed of at leasttwo LED arrays each having an LED array 101 and a fluorescent materiallayer 108 covering the LED array, and a projection optical system 51including reflection surfaces 103 which are multireflectors divided intoa plurality of small reflection regions, a shade 104 and a projectorlens 105.

As depicted in FIG. 9, the light source is positioned to make itsprojecting direction (light emitting surface) upward. The reflectionsurface 103 is a spheroidal reflection surface whose first focal pointis set near the light source and second focal point is set neat theupper edge of the shade 104, and it is positioned to cover the side andthe front of the light source so that lights from the light sourceirradiate the reflection surface 103.

As depicted in FIG. 9, the reflection surface 103 projects the lightsource images 106 of the plurality of the LED arrays 100 of the lightsource to the front of a vehicle and is designed to project the lightsource images 106 of the LED arrays 100 on the virtual vertical screen(projection surface) 107 which faces the front of the vehicle.

The shade 104 is a shading part for shading a portion of reflected lightfrom the reflection surface 103 to form a cutoff line suitable for aheadlamp. The shade 104 is disposed between the projection lens 105 andthe light source 102, placing its upper edge near the focal point of theprojection lens 105.

The projection lens 105 is positioned on the front of the vehicle andirradiates the reflected light from the reflection surface 103 onto theprojection surface 107.

When the low resistivity regions LR and the high resistivity regions HRare configured to distribute as in the plan view of FIG. 2A, brightnessdistribution gradually decreasing from the lower side to the upper sidecan be obtained. Head lights of automobiles are required to illuminenear portions more brightly than far portions. The above-mentionedbrightness distribution is fitted for head light of an automobile.

All examples and conditional language recited herein are intended forpedagogical purposes to aid the reader in understanding the inventionand the concepts contributed by the inventors to furthering the art, andare to be construed as being without limitation to such specificallyrecited examples and conditions, nor does the organization of suchexamples in the specification relate to a showing of the superiority andinferiority of the invention. Although the embodiments of the inventionhave been described in detail, it should be understood that the variouschanges, substitutions, and alterations could be made hereto withoutdeparting from the spirit and scope of the invention.

What are claimed are:
 1. A semiconductor light emitting devicecomprising: a semiconductor lamination including a p-type semiconductorlayer, an active semiconductor layer, and an n-type semiconductor layer;an opposing electrode structure including a first electrode structureformed above the p-type semiconductor layer, and a second electrodestructure formed above the n-type semiconductor layer; and a brightnessgrade producing structure including a surface layer of one of the p-typesemiconductor layer and the n-type semiconductor layer and producingbrightness of emitting light gradually changing from one edge to anopposite edge of a light output plane, wherein the brightness gradeproducing structure includes high resistivity regions including plasmadamaged regions and low resistivity regions including regions of noplasma damage in the surface layer.
 2. A semiconductor light emittingdevice comprising: a semiconductor lamination including a p-typesemiconductor layer, an active semiconductor layer, and an n-typesemiconductor layer; an opposing electrode structure including a firstelectrode structure formed above the p-type semiconductor layer, and asecond electrode structure formed above the n-type semiconductor layer;and a brightness grade producing structure including a surface layer ofone of the p-type semiconductor layer and the n-type semiconductor layerand producing brightness of emitted light gradually changing from oneedge to an opposite edge of a light output plane, wherein the brightnessgrade producing structure includes a plasma damaged region in thesurface layer, the plasma damaged region changing depth from one edge toan opposite edge of the light output plane.
 3. The semiconductor lightemitting device according to claim 2, further comprising an opticalsystem for projecting lights emitted from the light output plane towarda predetermined direction.
 4. A method for manufacturing a semiconductorlight emitting device capable of emitting lights with graded brightness,the method comprising: growing a semiconductor lamination on a growthsubstrate, the semiconductor lamination including a p-type semiconductorlayer, an active semiconductor layer, and an n-type semiconductor layer;forming a brightness grade producing structure including a surface layerof at least one of the p-type semiconductor layer and the n-typesemiconductor layer and producing brightness of emitting light graduallychanging from one edge to an opposite edge of a light output plane; andforming an opposing electrode structure including a first electrodestructure formed above the p-type semiconductor layer, and a secondelectrode structure formed above the n-type semiconductor layer, whereinthe forming the brightness grade producing structure includes forminghigh resistivity regions including plasma damaged regions and regions ofno plasma damage in the surface layer.
 5. A method for manufacturing asemiconductor light emitting device capable of emitting lights withgraded brightness, the method comprising: growing a semiconductorlamination on a growth substrate, the semiconductor lamination includinga p-type semiconductor layer, an active semiconductor layer, and ann-type semiconductor layer; forming a brightness grade producingstructure including a surface layer of at least one of the p-typesemiconductor layer and the n-type semiconductor layer and producingbrightness of emitting light gradually changing from one edge to anopposite edge of a light output plane; and forming an opposing electrodestructure including a first electrode structure formed above the p-typesemiconductor layer, and a second electrode structure formed above then-type semiconductor layer, wherein the forming the brightness gradeproducing structure includes forming a plasma damaged region in thesurface layer, the plasma damaged region changing depth from one edge toan opposite edge of the light output plane.
 6. The method according toclaim 4, further comprising assembling an optical system for projectinglights emitted from the light output plane toward a predetermineddirection.
 7. The semiconductor light emitting device according to claim2, further comprising an optical system for projecting lights emittedfrom the light output plane toward a predetermined direction.
 8. Themethod according to claim 5, further comprising assembling an opticalsystem for projecting lights emitted from the light output plane towarda predetermined direction.